Product with multiple functions such as on board technology, e.g. panel or pipe with enhanced systems within

ABSTRACT

The invention relates to a product, which may take a wide variety of forms but which is exemplified by a pipe or a panel. The product has a first function, such as that normally expected of a pipe or a panel, and a second function different from the first. The second function is chosen from a group consisting of: delivery of energy, for a first purpose, delivery of energy for a second purpose, delivery of data for a first purpose, delivery of data for a second purpose, switching. The product has incorporated in its means capable of enabling the product to be used as medium to perform the second function. The invention also concerns a method of manufacturing the products.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/347,168, filed Jan. 17, 2003, which is a continuation ofInternational Patent Application No. PCT/AU01/00876, filed Jul. 19,2001, which claims priority from Australian Patent Application No.PQ8855, filed Jul. 19, 2000. All of these prior applications are herebyincorporated by reference herein in their entireties.

TECHNICAL FIELD

This invention relates to the enhancement of products generally with aview to enabling a product to perform or be used in an improved manner.

BACKGROUND ART

The concept of “on board technology” was introduced in InternationalPatent Application No. PCT/AU99/00185 (WO 99/47819) and the contents ofthis are imported herein by reference.

In WO 99/47819, an aspect of “on board technology” was disclosed inconnection with elements such as building panels, where one panel hadprotrusions and another recesses or pits adapted to receive theprotrusions, so that one panel could be fixed to the other.

The present application deals with other aspects of “on boardtechnology” which, as will be apparent from the description below, hasfar, far wider application than that of the building industry.

DISCLOSURE OF THE INVENTION

A product being a pipe, panel, sheet or partly formed product, theproduct having a first function as, respectively, a part, panel, sheetor partly formed product and a second function different from the firstthe second function being two or more of those chosen from the groupconsisting of delivery of energy for a first purpose, delivery of energyfor a second purpose, delivery of data for a first purpose, delivery ofdata for a second purpose and switching, wherein there is incorporatedin the product or in part thereof means capable of enabling the productto be used as a medium to perform the second function.

In relation to this first act, the invention also provides a method ofmanufacturing the product, the method including the step of adding to orincorporating in the product, or in an element of it, the means capableof enabling the product to be used as the medium to perform the secondfunction.

The product with which the invention is concerned may be chosen from anextremely broad range, the method of the invention having wideapplication. By way of non-limiting example the following may bementioned: panels, building boards, cladding, structures (such as walls,floors, buildings) and pipes.

Such a product may be, for example, a panel from which a wall isconstructed, or cladding on a satellite. Other types of product arewithin the scope of this invention, as will be appreciated by oneskilled in the art.

The first function of the product of the invention is the normalfunction of the product. For example, the product may be a panel or apipe and the first function is that normally expected of a panel or apipe.

The second function which is chosen from the specified group can enhancethe product by enabling it to be a passive, or active part of a largersystem which includes, for example, delivery of energy and data. Thesecond function may also enable improved assembly of the product itselfto other structures.

In relation to the aspect of the second function being delivery ofenergy, this can involve delivery of many types of energy. The meanscapable of enabling the product to be used as a medium to deliver energyare, for example, buses applied to the product or elements of it,electrical energy transfer means, and pneumatic or hydraulic energytransfer means.

The delivery of energy may be for a first purpose, such as meltingadhesives. The delivery of energy may be for a second purpose, such asactivation of a fastener. The first purpose is different from the secondpurpose.

In relation to the aspect of the second function being delivery of data,this may involve various data transfer means, for example transfer ofdata in a networking environment. Delivery of data for the first purposemay be, for example, to unlock a fastener. Delivery of data for thesecond purpose may be, for example, to lock the fastener.

The two or more second functions may be carried out using a singlemedium, such as a cable, for example.

In relation to the second function being switching, this may involveswitching of the product or an element of it between different states.For example, the product may be a pipe which is switchable between anopen and a closed state so that material or fluid is able or unable toflow through the pipe. Switching may also involve imprinting the productor an element of it with a knowledge or logic of how to fix itself toanother object, or of steps to be taken in a procedure.

Optionally, in the product of the invention the second function may alsobe chosen from the group consisting of recordal, storage, processing andcommunication. The second function may involve two or more of theforegoing.

The aspects of recordal and storage may include memory, such as therecordal of data relating to the product or its elements, perhaps in arandom access memory (RAM). Recordal may also relate to recordal of amemory for the product or an element in it, such as a material, which isimprinted with a memory whereby it has an ability to return to aparticular state or shape.

The processing aspect may involve processing of data or instructions.For example, built-in logic may cause the product or part of it to referto data (such as data in a memory) and to perform an operation. Anexample is a structure which is serviced on a first occasion, duringwhich fasteners for the structure are opened in a particular order. Theproduct or an element of it may retain the memory of that order andcause the fasteners to open in the same order on the next occasion onwhich the structure is serviced.

Communication may be with a third party, a remote database, a globalpositioning system or a sensor system (sensing heat, proximity, etc.),for example.

In relation to the method of the invention, the adding step ispreferably performed during what would be regarded as the normalmanufacturing process, although the adding step may also be performedpost-manufacture.

By use of the product of the invention, it may be possible to improveassembly and/or operation or function of the product. By way ofnon-limiting example, assembly may be improved by enabling assembly totake place remotely, or by triggering an assembly step when a product orelement of it is placed in a particular juxtaposition.

Operation may be improved in various ways, such as by enabling remoteoperation of a valve or tap, for example.

The product of the invention may include at least one fastener, thefirst purpose comprises the delivery of energy or data to the fastenerand the second purpose comprises the delivery of energy adapted toaffect the shape of the product or the relationship of the product toanother product.

Certain brief illustrations of the methods and products of the inventionare set out below, followed by more detailed examples described inconnection with the drawings.

In connection with the invention in which the second aspect is deliveryof energy, the product may be a composite panel comprising conductivelayers sandwiching plastic layers, or layers of some other insulatingmaterial. Each plastic layer may be printed with or include circuitrywhich, when connected by a conducting fastener or other means passingthrough the panel, connects the circuitry to effect a desired result inenergy delivery.

As a further example, a computer circuit board may be manufactured withholes drilled through it. The board is imprinted with means which causesthe board to fuse to any material which is inserted in the drilledholes.

As a further illustration of energy delivery, the product may be a pipeof non-conducting material, except that during manufacture the pipe isextruded with one or more wires or metal plated areas inside or out, sothat when a second means causes activation, the pipe can conduct anelectrical current. The second means may be water passing through thepipe (in the case where the wires or metal plating are inside the pipe).This method of energy delivery may be less costly and/or more efficientthan other more traditional methods. The pipe may also deliver data.

In connection with the invention where the second aspect is switching,an illustration is as follows. A pipe, such as that described abovewhich provides delivery of energy and/or data may include means whichenables material flowing through the pipe to be halted. For example, thepipe may include a valve which can be opened or closed preferably byremote activation, some examples of which arm included in WO 99/47819.As a further example, the energy delivered via the pipe may bepneumatic, combined with switching to open or close a valve in the pipe.

In another aspect, the invention also provides a panel including aplurality of projectile capsules, each having a projectile element andan impelling material adapted to project the projectile element out ofthe panel upon activation of the impelling material.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in connection with nonlimitingexamples illustrated by the accompanying drawings, in which:

FIG. 1 is a perspective view of a first example of the method andproduct of the invention;

FIGS. 2 and 3 are perspective views of a second example, being a panelfor a satellite shown in FIG. 4;

FIGS. 5 and 6 are end views of a third example;

FIG. 7 is a top view of the pipe of FIG. 6;

FIG. 8 is a side elevation of the pipe of FIG. 6;

FIG. 9 is a detail of a coupling for the pipe of FIGS. 5 and 6,involving delivery of data;

FIG. 10 is a detail of a coupling for the pipe of FIGS. 5 and 6,involving delivery of power;

FIG. 11 is a variation of the arrangement in FIGS. 7 and 8, showing acoupling forming a “T” intersection;

FIG. 12 is a perspective view of a fourth example;

FIG. 13 shows a detail of FIG. 12;

FIG. 14 is a perspective view of a further example, being a panel;

FIG. 15 shows the sandwich type of construction of the panel in FIG. 14;

FIG. 16 shows part of the panel of FIGS. 14 and 15 after part of it hasbeen curved;

FIG. 17 is a perspective view of a panel similar to that in FIG. 14;

FIG. 18 shows the panel of FIG. 17 being shaped to a curve;

FIG. 19 shows two panels as in FIG. 17 attached to a structure;

FIG. 20 is a perspective view of a panel having an external energysource;

FIG. 21 is a cross sectional view of a fastener included in FIG. 20;

FIG. 22 is a perspective view of a panel similar to that in FIG. 20 buthaving an internal power supply and a surface data grid;

FIG. 23 shows a perspective view of a panel very similar to that in FIG.20 but with an internal power source (not shown) and expanding on detailof the fastener;

FIG. 24 shows in cross sectional view the further detail of the fastenerin FIG. 23;

FIG. 25 is a perspective view, partly cut away, of a further example ofa product being a panel;

FIG. 26 is a cross sectional view of part of the panel of FIG. 25,showing in detail one of the fasteners;

FIG. 27 is a perspective view of a further panel having an internalpower supply and a fastener addressable by a broadcast system;

FIG. 28 is a sectional detailed view of one of the fasteners in FIG. 27;

FIG. 29 is a perspective view of a wireless data switched device havingan internal power supply, a communication device and a processor/memory;

FIG. 30 is a perspective view of a further example of a productaccording to the invention;

FIGS. 31 to 33 show a sequence relating to a first form of projectiledevice which can be used in relation to the device of FIG. 30;

FIGS. 34 and 35 show a second form of projectile device; and

FIG. 36 shows a perspective partial view of a cladding in whichprojectile devices similar to those in FIGS. 31 to 35 have beeninstalled as anti-personnel devices.

DETAILED DESCRIPTION OF THE DRAWINGS

In FIG. 1, the product is plasterboard panel 10, shown in the process ofmanufacture. The first function of panel 10 is that of an internal panelused for building. The second function is that of power delivery.

During manufacture, calcium sulphate slab 12 travels in the direction ofarrow 14, assisted by rollers 15. As it does so, wire, tape, fibre orother suitable conductive material 16 is fed from spools 18 onto slab12. Drill heads 20 on arm 22 drill apertures 23 through wire 16.Fasteners 24 are inserted by head 26 into apertures 23 as they passunder head 26.

Paper or other suitable material 28 is fed from roll 30 to overlie wire16 and deposits 24. If desired, paper 28 may incorporate a bus ornetwork.

If desired, the underneath of panel 10 may be treated in the same way.

Reference is made to FIG. 2, in which panel 32 is made of suitableinsulating material and carries on board buses 34 and electricallyactivatable fasteners 36.

Panel 32 is initially flat as shown in FIG. 2, but through theapplication of electric or heat energy is caused to change shape asshown in FIG. 3. Further details of how panel 32 may be caused to changeshape are set out in relation to FIGS. 14 to 16 below.

Panel 32 may be fastened to satellite substructure 38 (refer FIG. 4) byactivating a power supply (not shown), causing fasteners 36 to attach tosuitable sites (not shown) on substructure 38. Buses 34 deliver energyfrom the power supply to fasteners 36.

Also incorporated in panel 32 are on-board data network 40, aerial 41,memory/processor module 42 and communication module 43 (eg, operatingvia a global satellite positioning system). Local processor 44communicates with contact switch 46. Fasteners 36 include monitors (notshown).

As shown in FIG. 4, panels 32 may be assembled onto substructure 38 inan inhospitable environment such as space to form a total assembly. Eachpanel 32 is sequentially fixed, via fasteners 36. Telemetry is used toeffect fastening; energy is delivered by buses 34 to fasteners 36,activated via data network 40 on software command from memory/processormodule 42. All parts of the assembly may be monitored, until such timeas the assembly is disassembled, which may also be carried out remotelyusing the components built into panels 32.

Shown in FIG. 5 is a pipe which can deliver energy and data.

In this example, pipe 50 has built-in power cables 52 and data cables54. Pipe 50 is conveniently joined by coupling 56. Coupling 56 includesconnector 58 for power take off or supply 62 and connector 60 for datainput and/or output 64 (refer FIG. 6).

FIG. 7 shows two couplings 56 in line on a pipe 50, illustratingattachment by data input/output 64, while FIG. 8 shows a correspondingview for power take off/supply 62. More detail of couplings 56 is shownin FIGS. 9 and 10, below.

Turning now to FIG. 9, this shows in more detail couplings 56 involvingdelivery of data and also “switching”, being the opening and closing ofvalve 66. In FIG. 9, valve 66 is shown in the closed position.

Pipe 50 includes in its wall data cable 54 which is connected toprocessor 68 by data contact 70. Processing 68 communicates withconnector 60, into which data input/output plug 64 may be inserted.

Valve 66 is switched between the open and closed positions by means ofactivating coil 72 which in this embodiment is activated by datadelivery via processor 68.

This embodiment also shows couple 74 which can provide heating to fusecoupling 56 to pipe 50 by melting adhesive (not shown) when coupling 56is first joined to pipe 50.

The view in FIG. 10 is at right angles to that in FIG. 9.

In FIG. 10, valve 66 is shown in the open configuration after theoperation of activating coil 72.

Power cable 52 communicates with connector 58 via power contact 76.Power take off or supply 62 can be inserted in connector 58.

It will also be appreciated that it may be possible to combine powercable 52 and data cable 54 into a single conduit in pipe 50.

Whereas in FIGS. 7 and 8 couplings 56 were shown in line, it is possibleto have a similar coupling 76 which permits a “T” intersection for pipes50 and this is shown in FIG. 11. Pipes 50 will thus carry water (orother fluid) as well as power and data.

The arrangement in FIG. 11 is shown in an application in a garden.Humidity sensor 78 feeds data as to soil humidity via connector 60 intodata cable 54 (not shown in this Figure). Data received from sensor 78can cause switching of valve 66 so that valve 66 opens to allow the flowof water to the garden when soil humidity drops below a set value andcauses closing of valve 66 when soil humidity has exceeded a chosenvalue.

Power delivered by pipe 50 can be used to power garden lights, one ofwhich is shown at 80.

The next example at FIG. 12 shows a product being panel 82, which hasincorporated in it conductive strips 84. Panel 82 is to be affixed tostuds 86 mounted in track 88. Each of studs 86 includes a hot melt stripfastener 90 which is detailed in FIG. 13.

Power from source 92 is applied to panel 82 via clip 94 and earthed bythe application of clip 96 to track 88. When panel 82 is placed inposition against studs 86 the circuit is completed and power from powersource 92 flows to heat fasteners 90 and adhere panel 82 to studs 86.

Alternately, conductive strips 84 can be specifically activated remotelyvia remote switch 98 in each of conductive strips 84 (only one is shownin FIG. 12), remote switch 98 being activated by a signal fromtradesman's tool or other source 100.

FIG. 13 shows detail of hot melt strip fastener 90. Hot melt adhesive102 is contained in channels 104 of fastener 90. Power flowing throughconductive strips 84 when the circuit is completed as already describedheats adhesive 102 which flow through apertures 106 to contact panel 82and to effect adhesion. Hot melt adhesive 102, once cooled, may create apermanent bond or may create a reversible bond, so that if it is desiredto remove panel 82 from studs 86, it is merely necessary to applysufficient power to again melt the adhesive.

Turning now to FIG. 14, this illustrates the principle which can permittotal or partial curving of a panel, such as discussed in connectionwith FIGS. 2 to 4, above. In the embodiment shown in FIGS. 14 to 16,panel 108 is made of sandwich construction, such as metal layers 110 andplastic layers 112. Centrally located is a layer of heat activatableadhesive 114, which is capable, when softened through the application ofheat, to permit panel 108 to be curved and reset.

As can be seen from FIG. 14, panel 108 has incorporated in it wires orother fibres 116. When energy is applied to wires 116, heat is createdsufficiently to soften adhesive 114.

Panel 108 also has internally embedded fasteners 118.

When heat is generated by means of the matrix formed by wires 116, panel108 can be shaped as desired, either before or during application ofpanel 108 to its desired site, such as satellite substructure 38 in FIG.4. Fastening can take place by means of embedded fasteners 118, forexample in one of the manners described in application WO99/47819. Whenenergy is no longer applied to wires 116, panel 108 can set in its newshape. This procedure can be reversible if desired. It will beappreciated that in FIG. 16 only part of panel 108 is shown, forconvenience.

In FIG. 17, panel 120 has, like panels 108 in FIG. 14, wires 116 andembedded internal fasteners 118. In the embodiment in FIG. 17, however,panel 120 also includes heating elements 122.

As was the case with the previous embodiment shown in FIG. 15, panel 120is of sandwich construction, with metal outer layers and plastic innerlayers separated by a line of hot melt adhesive. Power is supplied toheating elements 122 via wires 116 to cause panel 120 to curve from theflat form shown in FIG. 17 and in dotted outline in FIG. 18 to thecurved form shown in FIGS. 18 and 19.

FIG. 19 shows two of the curved panels 120 fastened to an underlyingstructure 124 by activation of fasteners 118.

Turning now to FIG. 20, panel 126 is of sandwich construction, havingmetal outer layers 110 and foamed plastic internal layer 112. In thisexample, panel 126 delivers electrical energy from an external source 92to fasteners 128.

A detail of a fastener 128 is shown in FIG. 21. Fastener 128 iselectrically activated in two ways. Fastener 128 has electrical contacts130 and 132 which, when fastener 128 is installed in panel 126, makecontact with metal layers 110. When fastener 128 is first inserted incavity 134 in panel 126, hot melt heater 136 can be electricallyactivated by closing switch 138 on power source 92, to melt adhesive 137to secure fastener 128 in cavity 134. Fuse 142 deactivates heater 36 ifthe melt procedure is to be irreversible. If switch 138 is then turnedoff, the next time it is turned on, it can cause fastener 128 to releaseor fasten, as the case may be. Fastener 128 will thus lock or releasefastening component 140. Fastener 128 may fix or release reversibly orirreversibly, as desired.

FIG. 22 shows panel 144 being similar to panel 126 in FIG. 20, exceptthat panel 144 has an internal power supply and a surface data grid 146.Surface data grid 146 can be used to instruct fastener 128 to lock orunlock, as required.

In FIG. 23, panel 148 delivers data, assisted by an external powersupply (not shown). Data is delivered by data wires 150, being “y”coordinate wires and data wires 152, being “x” coordinate data wires.Fasteners 154 are located at addressable cartesian coordinates locatedat the intersection of wires 150 and 152 and thus fasteners 154 can beaddressed individually.

As shown in FIG. 24, fastener 154 includes electrical contacts 130 and132 for making contact with metal layers 110, hot melt heater 130 formelting hot melt adhesive 137 and remotely activatable element 156 whichcan engage or disengage fastening component 158.

In FIG. 25, panel 160 has an internal power source, battery 162. Panel160 is composed of several layers, as shown in FIG. 26. Fastener 164 isconnected to power layer 166 and data layer 168, with layer 170 actingas an earth. Panel 160 can have an outer layer of plastic 172.

Locking and unlocking of fastener 164 may be instructed via datadelivery through data layer 168, power being supplied through powerlayer 166 powered by battery 162.

In FIG. 27, panel 174 is a metal/foam/plastic laminate with an internalpower supply, battery 162. Energy delivery is effected by metal layer110 or a second layer 176 located under this.

Fastener 178 is activatable by a broadcast which is received via addresssystem chip 180 which in turn activates switch 182.

With reference to panel 174 in FIG. 29, this includes communicationdevice 184 and processor/memory 186 as well as battery 162.

Turning now to FIG. 30, panel 188 has embedded in it one or moreprojectile fasteners 190. This may be of the type, for example shown inFIGS. 31 to 33 or in FIGS. 34 and 35.

In FIGS. 31 to 33, fastener casing 192 encloses nail 194, the tip 196 ofwhich is visible in the surface of panel 188. High velocity explosive198 in the base of fastener casing 192 is activated in a suitable way(eg, remotely) to explode nail 194 as shown in FIG. 33. This can beused, for example, to secure panel 188 to another structure (not shown).

As an alternative to the use of nail 194, fastener casing 192 mayinclude screw 200, having turbo head 202. Use of a low velocityexplosive under turbo head 202 will cause screw 200 to rotate and moveupwardly to the position shown in FIG. 35. This can be used to screwpanel 188 to another structure (not shown).

It will be noted that, as shown in FIGS. 32 and 35, nail 194 and screw200 are retained within casing 192 because of the size of opening 204 incasing 192 and the size of the heads of nail 194 and screw 200respectively. FIG. 36 shows a version of the invention in whichprojectiles such as nail 194 and screw 200 are not retained in casing192.

In FIG. 36, one or more of panels 206 include casings similar to casing192 in FIGS. 31 to 35, except that the projectiles may be whollycontained therein and may not penetrate the surface until activated.

The projectiles used may include items such as nails 194 and screws 200and also metal balls 208 or other items of shrapnel.

The opening 204 in casing 192 and the dimensions of the projectile ineach case are adjusted so that the projectile, once fired, leaves casing192 entirely.

Panels 206 in FIG. 36 can be useful to deter graffiti or asanti-personnel means to cause damage to personnel who are not authorisedto approach the panel in question.

The projectiles are preferably activated by high velocity explosive,which in turn is triggered by an ultrasound or other detector. When thepanel is in “alert mode”, and the detector detects unauthorisedapproach, the projectiles will be fired at the intruder.

INDUSTRIAL APPLICABILITY

It will be apparent from the above that the products and method of theinvention have wide applicability in many fields of industrialendeavour.

1. A panel including a plurality of projectile capsules, each capsulehaving a projectile element and an impelling material adapted to projectthe projectile element out of the panel upon activation of the impellingmaterial, wherein the projectile element is shrapnel or a metal ball andwherein the impelling material is adapted to be activated by a detectorof motion, sound, or ultra-sound.